AI-Powered KUKA Robots Unload Truck Trailers, Streamline Warehousing at 3PL Company

States Logistics Services Inc., a third-party logistics provider with over 800 employees across multiple facilities, partnered with Contoro Robotics in 2023 to deploy an autonomous robotic system for unloading floor-loaded semi-truck trailers. The system uses a KUKA KR IONTEC industrial robotic arm equipped with Contoro Robotics' AdaptAI software, featuring AI-powered cameras and sensors that map the interior of trailers and generate hundreds of optimized, collision-free picking paths. Contoro's DuoGrasp gripper grabs boxes from two sides simultaneously, handling payloads that fixed gantry systems cannot manage as effectively. Once a trailer is positioned at the dock, the robot identifies and locates cases using AI-guided vision, picks them up and places them on a powered conveyor that moves cases out of the trailer, where a secondary robot then palletizes them. The facility handles over 50 truck-trailer containers per month, and prior to automation, two to three employees working an eight-hour shift could only offload two or three containers. Now the robots handle four to five containers per shift. The solution also addresses refrigerated containers with grooved floors for air circulation, requiring a modified mobile base and perception array adjusted for the unique wall and air handling environment. The robotic handling creates more consistent pallet builds, reduced product damage risk, and lower labor and injury-related costs. The deployment follows a robotics-as-a-service model with predictable per-trailer pricing, shifting costs from capital expenditure to operating expenditure.